Process for making tampons



Sept. 28, 1943. v s. P. BAILEY 2,330,257

PROCESS FOR MAKING' TAMPONS Filed Jan. 14, 1939 2 sheets-sheet 1 lINVENTOR .5T/)CY P. BAILEY ATTORN EY Sept. 28, 1943. s. P. BAILEY2,330,257

PROCESS FOR MAKING TAMPONS Filed Jan. 14, 1939 2 Sheets-Sheet 2 INVENTOR57746)/ P 9L/ EY BY ATTORNEY Patented Sept. 28, 1943 PROCESS FOR TAMPONSStacy I. Bailey, New York, N. Y., assignor, by mcsne assignments, toJohn F. Wallace, New

York, N. Y.

Application January 14, 1939, Serial No. 250,973

4 Claims.

This invention relates in general to -a process for making tampons andin particular to tampons adapted for insertion into body cavities forthe absorption and retention of liquid secretions and to correlatedimprovements designed to enhance the structure, function and utility ofsuch tampons. Although having other fields of usefulness, the presentarticle probably has its greatest utility as a vaginal tampon for theabsorption and retention of menstrual discharges, being used in place ofan external sanitary napkin or pad.

'I'h'e object of the invention is to provide an efcient and practicalprocess for ymaking a tampon which has relatively small initialdimensions for economy in shipment, storage and handling, which isconvenient in carrying and inserting, and which is adapted to expandinto a relatively large, soft and resilient body to fill the vagina andconform to the shape thereof but which may be readily, conveniently andcompletely with'- drawn from the vagina when required,the process beingcharaterized in initially compressing a substantially circular layer ordisc of absorbent ibrous water-impermeable material so that the centreof this layer forms the lower end of the tampon, thereafter gatheringthe upper portion or edges of this layer inwardly to form a cup shapedbody, and subsequently conforming the cup sh'aped body to asubstantially cylindrical body under pressure so that said cylindricalbody will hold its cylindrical shape While dry solely as a result ofsuch compression but will expand when wet to form a substantiallyconical body as a result of the expansion of the previously gathered andcompressed upper portion.

Other objects of the invention will in part be obvious and will in partappear hereinafter.

In accordance with the present invention the above mentioned objects areachieved by forming a tampon comprising a layer of brous absorbentmaterial compressed into a cylindrical body having a relatively smalldiameter and which is adapted to expand when the pressure is releasedinto a relatively large and soft conical shaped body having aconstricted lower end.

facilitates the withdrawal withoutirritation.

I have found that the rm dense structure, the

'Ih'e invention accordingly comprises an article having the elements andrelation of elements one to another and a process having thesteps andthe relation of steps to one another all asdescribed in the followingdetailed description and the scope of the application of which isindicated in the claims.

For a. more complete understanding of the nature and of the objects ofth'einvention reference should be had to the accompanying drawings inwhich:

Fig. l represents a top plan view of a material from which oneembodiment of the tampon of the invention may be produced;

Fig. 2 is a view in section of the material of Fig. 1 taken along theline 2 2 thereof;

Fig. 3 is a view in section of another embodiment of the material forforming th'e present article;

Figs. 4 and 5 illustrate two steps in` a process of forming oneembodiment of the present tam- P011;

Fig. 6 is a view in section of the article of Fig. 5 taken along theline 6 6 thereof;

Fig. 7 is a side elevation in section of the ta pon of Fig. 5 afterexpansion thereof;

Fig. 8 is a partly finished tampon formed from the material shown inFig. 3;

Fig. 9 is a View of a material from which one embodiment of the tamponcan be formed;

Figs. 10 and 11 are views partly in section of one embodiment of thetampon package of the invention;

Fig. 12 illustrates one stage in a method of forming a second embodimentof the tampon of the invention;

Figs. 13 and 14 are views in section of a tampon formed in the deviceshown in Fig.v 12 before and after expansion, respectively;

Fig. 15 is a view in section of another material from which the secondembodiment of the tampon may be formed;

Figs. 16 and 17 are views in section of a tampon formed from thematerial shown in Fig. l5 before and after expansion respectively;

Figs. 18, 19, 20, 21 and 22represent as many views of the secondembodiment ofthe tampon;

Figs. 23 and 24 represent two views partly in section of anotherembodiment of the tampon package of the invention-, l A K According tothe present invention there is provided a tampon comprising an.labsorbent material temporarily compressed into a cylindrical body whichis adapted to expand into a conical shaped body whenv the pressure isreleased. By way of illustrating, but not by way of limiting the scopeof the invention, such a tampon will be illustrated by a description oftwo specific embodiments thereof. For convenience in reference theseembodiments will be designated in terms of their manufacture. Thatembodiment illustrated in Figs. 1 to l1 will be hereinafter designatedthe molded tampon and the embodiment illustrated in Figs. l2 and 23 willbe hereinafter referred to as the spirally wound tampon. It is to beunderstood, however, that other embodiments of the tampon may be formedhaving the same general shape and function as the two embodiments hereindescribed and illustrated.

The absorbent material employed in the present tampon may comprise anysuitable'vegetable tlbre, such for example as cotton, flax, wood, andthe like and silk, wool, hair, moss, either singly or in admixture andin the form of loose fibres or in the form of fabric or felted layer.

Refering to Figs. 1 to 11, inclusive, the molded tampon may beconsidered as comprising a layer I .of absorbent fibrous material havingthe edges gathered toward the center to form a substantially cup-shapedbody 2 and thereafter compressed to a substantially cylindrical body 3having a closed end 4 at the bottom and having a withdrawing meansattached to the lower end. The tampon is compressed temporarily so thatit expands when the pressure is released to a conic-rl shaped body.'I'he expression Iconical is intended to include frusto-conical andovate shapes.

In its simplest form the molded tampon may be formed from a singlelayer, preferably a disc, of absorbent material such as cotton as shownin Figs. 1 and 2 or from a plurality of layers of such material as shownin Fig. 3. A withdrawing means, such as a cord 5, is afllxed to thecenter as by sewing it through the layer I, the ends of the cordextending therefrom forming a loop 6. The layer I is shaped by suitablemeans so as to depress the center to form a tapered' closed bottom andto gather the sides upward to form a cup-shaped hollow body 2 asillustrated in Fig. 4. 'I'his cup-shaped body is subjected to lateralcompression suflicient to form a substantially cylindrical tampon 3 asshown in Fig. 5. When formed from a at disc of material the gathering ofthe sides will form folds 1 as shown in Fig. 4, which folds are pressedtogether to form the longitudinal pleats 'I' in the finished tamponshown in Figs. 5 and 6. The finished tampon has, in its compressedcondition, a dense ilrm structure, a smooth surface and a small diameterso that it may be readily inserted in the vagina by hand or by means ofa suitable applicator.

Instead of employing a layer of absorbent material and depressing thecenter thereof to form the cup-shaped body illustrated in Fig. 4, thecup-shaped body may be produced directly by spinning loose absorbentfibres in a known manner to form the molded hollow body 8 illustrated inFig. 8 which is then compressed laterally to produce a cylindricallyshaped tampon oi the type illustrated in Figs. 5 and 6.

In the now preferred embodiment of the molded tampon, generallyillustrated in Figs. l to 1l, the tampon comprises in addition to theabsorbent layer, a layer 9 of a water-impermeable material. When thetampon is formed from a single layer of absorbent material as shown inFig. 2, the water-impermeable layer is disposed on thatside which willbe on the outside of the finished tampon as shown in Fig. '7. When thetampon is formed from a plurality of layers of absorbent material, thewater-impermeable laycr is either on the. outermost surface or next theoutermost layer of absorbent material as shown in Fig. 9.

Referring to Fig. 2, the water-impermeable layer 9 may comprise aportion of the layer l of absorbent material which has been renderedimpermeable to water by coating or impregnating it in a plane extendingthroughout the layer I with a waterproofing substance such for exampleas a Wax, a resin, rubber-latex, a cellulose derivative and the like ora mixture thereof. Alternatively, the water impermeable layer maycomprise a sheet or lm 9' of waterproof material separate from theabsorbent layer and laminated thereto with a suitable adhesive ordisposed with or without adhesion between two or more absorbent layers Ias shown in Fig. 3. The sheet or film 9' may comprise, for example,metal foil, paper or a film formed of rubber, a cellulose derivative,insoluble gelatine, a synthetic resin and like film-forming materials.However produced, the layer of water-impermeable material is made thinor is plasticized to render it sufficiently flexible to enable theabsorbent material with which it is combined to be compressed to form asubstantially cylindrical tampon with- ;Jut breaking or cracking thewater-impermeable ayer.

The cylindrical shape of the tampon may be temporarily maintained 'bycompressing it to a cylindrical body under such pressure that the tamponwill not expand until wetted. Preferably, the tampon is compressed toless than the hmit of the compressibility of the absorbent material t0prevent loss of absorptivity. A suitable process and apparatus forcompressing the present `tampon is described in my copending applicationSerial No. 250,974 led Jan. 14, 1939.

Alternatively, the expansion of the compressed cylindrical body may berestrained by inserting the compressed tampon in an expansion-limitingmember such for example as a tube or cylinder. A preferred embodiment ofthe expansion limiting tube is a cylinder I 0 open at both ends andhaving an internal diameter just suiicient to accommodate thecylindrical tampon in its initially compressed condition as illustratedin Fig. 10. Advantageously, this tube may serve not only to maintain thetampon in the form of a compressed cylindrical body, but also as anapplicator tube to facilitate insertion of the tampon into a bodycavity. For such dual use the tampon 3 is forced into one end of thecylinder I0 to the position shown in Fig. 10. A suitable ejector such,for example, as the rod I I shown in Fig. 10 is disposed Within the tubewith the end I2 adjacent the lower end of the tampon so that when the4rod II is forced through the tube, the tampon 3 will be ejectedtherefrom. The end I2 is preferably provided with a slot I3 throughwhich the withdrawing cord 6 may pass so that it extends lengthwise `ofthe tube I0 as shown. If the tampon has not been subjected to suicientpressure to prevent its expansion until wetted, it will expandimmediately upon being ejected from the tube I0 to form a. conicalshaped hollow tampon 3 as illustrated in Fig. 11-. If the tampon 3 hasbeen compressed under such pressure that it does not -expand untilwetted, the tampon as ejected will remain in a substantially cylindricalformv until it has been moistened by the body secretions whereupon i-twill expand substantially to the conical shape of the hollow' body 3' asshown in Fig. 7.

Generally speaking the spirally wound tampon of the invention is similarin structure and function to the molded tampon above described in thatit comprises a mass of absorbent material compressed to a cylindricalbody which is adapted to expand to a conical shaped body. Thisembodiment of the tampon may be readily produced by taking a narrowelongated strip of iibrous absorbent material 20 as shown in Fig. 12 andspirally winding or rolling this strip upon itself or upon a mandrel 2|'under suitable pressure which may be applied by means of a pair ofcompression rollers 22 which are positively driven. The cylindrical body28' thus produced has the cross section while compressed as shown inFig. 13 and after the pressure has been released the cross section asshown in Fig. 14. Alternately. this embodiment of the tampon may beproduced from a plurality of superimposed layers of absorbent material20 as shown in Fig. 15 wound simultaneously under pressure into acylindrical body as in the case of a single layer. The layer may bewound into a cylindrical body without pressure and the larger roll soproduced may then be compressed laterally into a body of smallerdiameter. If desired the edge 24 of the strip 20 may be left free orfastened to the body of the tampon after compression by use of asuitable water-soluble adhesive such as dextrine, gelatine, methylcellulose or the like. In the vagina the secretions will dissolvethe'adhesive thus breaking the seal and permitting the tampon to expand.Preferably,`the spirally wound tampon may comprise in .addition to theabsorbent layer a water-impermeable layer which may comprise a coatingor flexible sheet material as above described associated with theabsorbent layer so that the impermeable layer is preferably disposed onthe outside or adjacent the outside of the finished tampon. For example,in Fig. 15 there is illustrated in section two layers of absorbentmaterial 20 enclosing a coating or exible sheet of water-impermeablematerial 24. When this material is wound spirally under pressure into acylindrical body, the body has a cross section while compressed as shownin Fig. 16 and a cross section after the pressure is released asillustrated in Fig. 17. When the layer of water-impermeable material isa sheet material having a high degree of resiliency such for example asa relatively thick sheet of a cellulose derivative or of stiiT paper,the coiled sheet material will tend to uncoil and thus expand the tamponwhen the pressure is released forming a tampon having a hollow interioras illustrated in Fig. 17, This expanded hollow tampon shown in Figs. 17and 23 functions in a manner identical with the hollow molded tamponillustrated in Figs. 7 and l1 of the embodiment above described.

In order to insure that the spirally wound tampon will form a conicalshaped body after expansion, the present invention provides that thelower end is permanently restrained from expanding as by constrictingthis end by means of a band, cord or wire which may also serve as thewithdrawing means and/or by sizing the lower end suiilciently to preventfull expansion thereof. The lower end of the cylindrical body isconstricted while it is compressed so that this end will not expand whenthe pressure is released or will expand to less extent than theremaining portions of the tampon.

For example there are illustrated in Figs. 18 and 19 two ways toconstrict the lower end by means of a cord 5. As shown in Fig. 18 thewithdrawing cord is passed upward through the lower end 26 of the tamponand out through a l0 hole 21 in the covering and around the outside ofthe tampon and back through the hole 21, down through the center, thefree ends being tied in a loop 6. When the loop thus formed is drawnupon, the cord will tend to constrict the lower end of the tampon andwill insure that all of the material thereof will be withdrawn.Alternatively, as shown in Fig. 19 the cord 5 is passed through thelower end 26 of the tampon shown in Fig. 18 and out through a hole 21 inthe cover- 20 ing, then continues in the form of short loops 28 inwardlythrough and out of the covering layer and thus around the tampon backthro-ugh the opening 21 and down through the center, the free ends beingtied to form a loop 6. When the 25 loop is drawn upon it will tend togather the end of the tampon into folds as illustrated in Fig. 20, thusconstricting the lower end of the tampon and greatly facilitating itsremoval. The lower end may be sized with a water-insoluble binder 30such as glue, gelatine, a cellulose derivative and the like over thearea 29 as shown in Fig. 21, the binder being applied and dried beforethe pressure is released. Alternatively, the lower end may be bound by aband 3| as shown in Fig. 22, the band being made of a suitable insolublesheet material such for example as metal, a cellulose derivative,

foil, waterproof paper, and the like.

When any of the tampons illustrated in Figs. 18 to 20 are allowed toexpand, they will form a conical shaped body which may besubstantially'solid throughout as shown in Fig, 14 or have a hollowinterior and open upper end as shown in Fig. 17 according to the natureof the material from which they are formed.

As in the case of the molded tampon, the spirally wound tampon may becompressed sutilciently to maintain it in a compressed cylindrical shapeuntil wetted or it may be compressed to a lesser extent and placedwithin an expansion limiting member IU as shown in Fig. 23. Thus thetampon 3 may be disposed within a limiting tube |0 to the position shownin Fig. 22 and this tube may serve as both a container and applicator asabove described. If employed as an applicator, the tube is provided witha pusher rod Il as shown in Fig. l0 or with a concentric enclosed tube32 having one end resting against the low`er end of the tampon and theother end extending from the end of the expansion limiting tube IU. Whenthe tube 32 is pressed inwardly, the tampon 23 is ejected, the ejectedtampon expanding to a conical shaped body 3| as shown in Fig. 24. Theejected tampon 3| will be solid or hollow depending upon the method ofconstruction as above described. For example, if the tampon is formedfrom a material comprising a layer of absorbent material 20 and aflexible sheet of resilient water-impermeable material 25, thewithdrawing cord 5 will maintain the lower end in a constrictedcondition and prevent expansion, whereas the sheet material will expandthe other portion of the tampon to form a conical shaped hollow body asshown in Fig. 17.

The expansion limiting tube and the ejector tube are preferably formedby molding or shaping the tube of a material which will disintegrate inwater, such for example as gelatine, water-soluble cellulose ethers andwater-soluble resins, whereby the tubes may be readily disposed of bydisintegration in water.

It is to be understood that various embodiments may be made in thearticle and process of the invention. For example, in making the moldedhollow tampon, instead of shaping a layer of absorbent material one mayspin a cup-shaped body in a known manner from a mass of bres and thecup-shaped body so produced provided with a coating or casing ofwater-impermeable material oi.' similar shape, the composite cupshapedbody then being compressed laterally as above described. Superiorresults are obtained i1 the absorbent material used in the presenttampon is formed of fibres which are hetergeneously arranged and notaligned parallel whereby the strength of the absorbent material issubstantially uniform in all directions and the absorptivity likewiseuniform. 'Ihe absorbent layer and/or the nished tampon may be providedwith a suitable sizing for temporarily retaining thev form aftercompression, such sizing comprising preferably a water soluble non-toxicmaterial such for example as gelatine, gum, agar agar,v dextrine,Istarch, water-soluble cellulose ethers and the like, and/or the tamponmay be combined with a medicinal substance for deodorizing or medicatingit and/ or with a coating for lubricating it comprising for exampleglycerine, grease, petrolatum, cocoa butter and the like.

When the compressed cylindrical tampon of the invention is inserted in abody cavity it expands to form a conical shaped body substantially asshown in Fig. 8, thus closing completely the cavity and providing anabsorbent inner layer for absorbing secretions. When the expanded tamponis hollow and cup-shaped it retains excess liquid over that capable ofbeing absorbed, such liquid being preventedfrom escaping due to thewater impermeable layer 2. The expanded tampon may be easily withdrawnby means of the cord because it is conical in shape with the constrictedend at the bottom. Accordingly there is provided by the presentinvention a. tampon characterized by having a minimum of size with amaximum capacity for absorbing and holding liquid, and a maximum usefullife without leakage, a smooth outer surface and with a shape permittingboth an easy and convenient insertion and a complete withdrawal withoutirritation.

Having described my invention, what I claim as new and desire to secureby Letters Patent is:

1. A processor producing a tampon comprising compressing a substantiallycircular layer of absorbent, brous material so that the center of saidcircular layer forms the lower end of the tampon, gathering the edges ofsaid layer to form a cup-shaped body and compressing said bodytransversely to a cylindrical body under such pressure that thecylindrical body will hold its cylindrical shape while dry solely as aresult of said compression, but will expand when wet to form a conicalshaped body as a result of the expansion voi? the gathered andcompressed edges.

2. A process for making a. tampon comprising shaping a disc formed of alayer of absorbent, brous material and a layer of water-impermeablematerial into a cup-shaped body by depressing the center of said disc,gathering the edges and compressing said body transversely to a,cylindrical body under such pressure that the cylindrical body will holdits cylindrical shape while dry solely asfa result or said compression,but will expand when wet to form a conical shaped body as a result ofthe expansion of the gathered and compressed edges.

3. A process of forming a tampon comprising cutting a disc from a layerof absorbent, ilbrous material, depressing the center of said disc toform the lower end of said tampon, gathering the edges of said disc toform a cup-shaped body, and compressing said body transversely to acylindrical body under such pressure that the cylindrical body will holdits cylindrical shape while dry solely as a result of said compression,but will expand when wet to form a conical shaped body as a. result ofthe expansion of the gathered and compressed edges.

4. A process for forming a tampon according to claim 3, in which thecompression of said body is accomplished by 'drawing the bottom end ofthe tampon into a constricting tube which holds the tampon compressed inthe form of a cylindrical body, which body will expand to a conicalshaped body when it is ejected from said tube.

s'rAcY P. BAILEY.

